Device for handling individually packaged goods

ABSTRACT

The invention relates to an apparatus for handling individually packaged goods in an array-like, two-dimensional configuration. The apparatus has a plurality of conveying means arranged in the manner of an array. These conveying means, driven independently of one another at variable speed and in a selectable direction ensure the individual movement of the individually packaged goods to be processed. The control device, in conjunction with the image processing system, coordinates these individual movements in such a way that the randomly fed individually packaged goods can be separated, aligned, conveyed, sorted, stored and sequenced.

Apparatus for handling individually packaged goods The invention relatesto an apparatus for handling individually packaged goods according tothe preamble of claim 1. Here, handling is understood to mean separatingand/or aligning and/or sorting and/or storing individually packagedgoods, which are fed and discharged by transport means. Individuallypackaged goods are, amongst others, packages, packets, bundles ofperiodicals, containers, pallets and sack-like goods. The individuallypackaged goods are fed either unordered and lying beside one another,preprocessing ensuring that no individually packaged goods lie on oneanother, or the individually packaged goods are fed in separately atdefined intervals. Following handling by the apparatus, the individuallypackaged goods are discharged in an ordered fashion to furtherprocessing. The ordered discharge can be used to produce a specificorder (sequence) of the individually packaged goods at the output fromthe aforementioned arrangement, said sequence being necessary oradvantageous for further processing.

According to the current prior art, there is no apparatus which carriesout the functions of separation, alignment, storage, sorting includingsequencing in a space-saving manner with little outlay. EP 780328 A1 andU.S. Pat. No. 5,638,938 describe separating devices for packages. Thedisadvantages of these known solutions are their great requirement forspace, in particular overall length, and uncertain separation in thecase of packages of different sizes. Aligning individually packagedgoods at right angles to the conveying direction during transport bymeans of specific roller conveyors is prior art.

The sorting of individually packaged goods is at present implemented bymeans of various types of special techniques, which are all based on alinear or circular transport direction.

The following solutions may be mentioned: tilt tray sorters (see companypublications from Crisplant A. S., Beumer K G), transverse belt sorters(see Sandvik, Crisplant A. S), pusher sorters (Sandvik, Lippert), shoesorters (Dematic, TGW), popup sorters (Van der Lande; Dematic).

At present, individually packaged goods are stored or intermediatelystored manually or with mechanical support (by being stacked on thefloor, stored in racks by using fork-lift trucks), partly automated (inso-called straight-through stores, with manual or automatic loading), orfully automated in high-rack stores, which are loaded and emptiedautomatically by rack operating devices.

The invention specified in claim 1 is therefore based on the object ofproviding an apparatus for space-saving handling, which separates and/oraligns and/or stores and/or sorts the individually packaged goods,including doing so in accordance with a defined sequence. The array-likearrangement of the conveying means which convey the individuallypackaged goods in one plane in four directions at right angles to oneanother, and also the identification and continuous tracking of theindividually packaged goods on the array area creates the preconditionfor moving and aligning the individually packaged goods freely withoutcollision. The input or inputs and output or outputs are located at theedges of the array area. The movement is carried out in accordance withthe handling to be carried out. If, for example, at an inputindividually packaged goods to be separated are transported onto thearray area close beside one another and behind one another, then,following the determination of the orientation of the individuallypackaged goods, one item after the other is transported to an outputwith a defined spacing by means of specific activation of the conveyingmeans needed for this purpose, alignment of the individually packagedgoods at the same time being possible. If the individually packagedgoods are to be sorted, then images of the individually packaged goodsare recorded and the handling information, in this case addresses, isdetermined as sorting information. The transport to the outputsenvisaged in accordance with the sorting plan is then carried out.During these transporting actions, which if possible are also carriedout in parallel, continuous tracking of each individual item is carriedout, so that the movements can be carried out in a defined andcollision-free manner. If intermediate storage is necessary for thesequence, this is readily possible. The individually packaged goods canbe stored intermediately, as required, both in a specific storage areaand decentrally, it being possible for the store to be enlarged orreduced dynamically, and access to the stored individually packageditems is as desired, with high variability of the storage strategy.

The handling apparatus is therefore functionally very flexible and atthe same time very compact.

Advantageous refinements of the invention are presented in thesubclaims.

If the conveying means according to claim 2 is designed with a sphericaltransport part, which is mounted without a fixed axis and, for example,is driven electromechanically in such a way that the direction can beselected freely, then it is possible to accommodate many conveying meanson a specific array area and, as a result of the free choice ofdirection, to cover the shortest possible distances with theindividually packaged goods.

It is also advantageous, according to claim 3, to include the conveyingspeed and the acceleration and braking pattern in the control, in orderin this way to be able to coordinate movement operations better with oneanother and to minimize the transport times of the individually packagedgoods on the array area.

According to claim 4, it is advantageous to use a sensor device whichrecords the height profile, in addition to the image recording andevaluating device, for the reliable identification and separation of theindividually packaged goods, for example if they are adjacent to oneanother.

In order to track the movement of the individually packaged goods, itmay also be advantageous, according to claim 5, to equip the conveyingmeans with pressure sensors, which detect whether there is an item onthe conveying means.

The invention will be explained in more detail below in an exemplaryembodiment, using the drawings, in which:

FIG. 1 shows a schematic, blocked diagrammatic, three-dimensionalillustration of the handling apparatus

FIG. 2 shows a schematic plan view of the arrangement, representing thedivision into the functional areas of feeding, separating, sorting,storage and discharging

FIG. 3 shows a flow chart relating to handling the individually packagedgoods, with the following parts

FIG. 3a separation and start of sorting

FIG. 3b completion of sorting in outlets, including alignment

FIG. 3c storage

FIG. 3d production of an order (sequences)

FIGS. 4a-h show a simplified example to illustrate the handlingoperations in different phases.

According to FIG. 1, the individually packaged goods 1 fed in are movedseparately in any desired horizontal directions by means of amultiplicity of conveying means 7 which are arranged in a matrix-like orarray-like form and have spherical transport parts on which theindividually packaged goods are moved. Each individual conveying means 7is additionally characterized by a variable speed and variableacceleration. The following patents show examples of the configurationof this conveying means: U.S. Pat. No. 5,808,395 “Torque motor” and U.S.Pat. No. 5,410,232 “Spherical motor and method”.

All the conveying means 7 are driven or only those on which individuallypackaged goods 1 are located or will shortly be located. This principleis illustrated in FIG. 2. By means of the separately driven conveyingmeans 7 it is possible to produce defined spacings between theindividually packaged goods 1 fed in, and therefore to separate them ina controlled or monitored manner. In addition, there is the possibilityof aligning the individually packaged goods 1 as desired in the plane.For the specific control of the arrangement, it is necessary to identifyeach item 1 as it is fed in, that is to say mainly to record itsdestination information, and to detect the orientation and outline(form) of the item 1 and to track the item 1 by using these features.The device required for this is designated an image processing device 3.The image processing device 3 comprises an image recording device 4 andan image analyzer 5. The image recording device 4 is expedientlyarranged above the plane of the conveying means. The data with regard todestination information, present orientation and outline of theindividually packaged goods 1 is transmitted to a control device 6. Thiscontrol device 6 determines and coordinates, on the basis of implementedalgorithms and regular refreshing of the information about the currentstate by means of the image processing device 3, the movement sequenceof all the individually packaged goods 1 from their feeding-in untiltheir discharge to the subsequent processing. By using the conveyingmeans 7, the image processing device 3 and the control device 6, it ispossible to transport each item 1 from the feed point to the dischargepoint determined by the destination information. The algorithmsimplemented in the control device 6 ensure the parallel progress of thisprocess for all the individually packaged goods 1 which are fed into it,so that no collisions occur and a movement sequence is ensured which isoptimal in terms of distance and time. In order to store theindividually packaged goods 1, this transport process is carried out toa storage destination point, interrupted there for a defined timeinterval or resumed by means of a remove-from-store request initiated bythe control device 6. This process describes the storage function. Inthe course of removal from store and/or during transport to thedischarge point, it may be possible for an order of the individuallypackaged goods 1, defined previously or to be produced during theprocess, to be produced when said individually packaged goods 1 arriveat the discharge point, this being qualified by the availability ofmultidirectional transport, storage function and discrete control of thetransport path of individual items 1. This function is helpful, forexample, if the individually packaged goods 1 are to be offloaded into atransport means from the discharge point in the reverse order for theirfurther processing.

In the following text, the handling sequence will be explained by usingFIGS. 3a-d.

The sequence will be described for one item 1. For clarity, thesimultaneous handling of a plurality of individually packaged goods 1will not be presented, but it is clear that, for this purpose, parallel,continuous coordination of the movement sequences of the individuallypackaged goods 1 is carried out by the control device 6, with the aid ofthe image processing device 3 and, if appropriate, further sensors, inorder to avoid collisions. Following the feeding 10 of the item 1 bymeans of transport devices (not shown) at the feed-in point, theorientation and outline 11 are determined. At the same time, it is alsoestablished whether the item 1 has to be separated 12, since, forexample, it is lying close beside another item 1. If this is so, theseparation 12 is carried out. The handling information on the item (inthis case the address of the recipient as sorting information) isdetermined and, from this, the necessary handling 14. The item 1 is thentransported onward 15 and the appropriate sorting operation is started16. If, in this connection, the item 1 is to be transported to aspecific discharge point associated with the recipient address 20, thena check is made to see whether the orientation of the item 1 is correct21. If so, the item 1 is transported to the discharge point 23 anddischarged to external transport means 24. If not, further alignment 22is carried out prior to this. If, within the context of the sortingoperation 16, the item 1 is to be stored, then it is transported to astorage area 30 and stored there 31. Storage lasts until the item 1 iscalled, 32. Following the call, it is transported away 33, either to therelevant discharge point, if no sequencing is necessary, 34, ortransport 40 is carried out, in order to produce an envisaged order 41.For this purpose, there is a static and a dynamic variant. In the staticvariant, the item 1 is stored at a place corresponding to an order list42. Once all the individually packaged goods have been stored in theenvisaged order, 43, and there is a call from the storage area 44, thenthe entire order is transported to the envisaged discharge point 45. Inthe dynamic variant, a check is first made to see whether the totalquantity for the order has been registered 41. If this is not so, thenonward transport is delayed 47, which in an extreme case can mean astoppage. Following registration, the relative orientation of the item 1as compared with the orientation according to the order list is checked48. If it is too far forward, its transport is delayed again 49, ifnecessary as far as stopping it. If necessary, a lateral movement isadditionally carried out, in order that the correct, subsequentindividually packaged goods 1 can move up. Once the relevant item 1 hasreached the correct position, it is transported onward. Once the correcttotal order is present, a further decision is made as to whether thesequence is to be stored or transported directly to a discharge point51.

This general sequence will now be explained using a simple example withan exemplary quantity of goods.

The following components are present:

1. A transport means for discharging the goods

2. An apparatus according to the invention for handling

3. Eight transport means (identification TM I-VIII) for leading thegoods away and therefore, at the same time, final sorting positions atthe output from the apparatus

The exemplary quantity of goods consists of ten box-like individuallypackaged goods (identification 1-10).

The following handling tasks have to be implemented by the apparatus:

1. From the individually packaged goods identified by 1, 2, 3 and 4, asequence corresponding to the order of the numbering is to be produceddynamically, and this sequence is to be fed to the transport means (TM)VIII.

2. Item 5 is to be fed to TM II.

3. Item 6 is to be fed to TM I.

4. Item 7 is to be stored and then fed to TM V.

5. From the individually packaged goods 8, 9 and 10, a sequence in theorder of the numbering is to be produced statically, and this is then tobe fed to TM IV without further storage.

In addition to the handling tasks represented above, the individuallypackaged goods are to be aligned by the apparatus in accordance with thehandling tasks.

FIG. 4a shows the initial state. The individually packaged goods 1 to 10are fed to the device in a single layer, in an unordered sequence andwith a very wide range of horizontal alignments by the transport means“feed”, that is to say are fed in. When they arrive on the apparatus,the orientation of the individually packaged goods and their distancefrom one another are determined. From this information, the controldevice 6 determines the necessary movement sequences for each individualitem.

FIG. 4b shows the start of the separation process. Once the individuallypackaged goods have been separated, their destination, that is to saythe final sorting point—here the transport means I-VIII—is identified bymeans of the image processing device 3 and the control device 6, and theappropriate handling tasks are linked to them.

FIG. 4c illustrates the start of the sorting operation, that is to saythe individually packaged goods are moved in a targeted manner to theappropriate final sorting point or an intermediate destination withinthe apparatus (here, for example, the storage locations for the staticsequencing). The individually packaged goods have left the transportmeans “feed”. The separation operation has been completed. At the sametime, the alignment of the individually packaged goods is carried out inaccordance with the handling task. This alignment operation is carriedout during the entire handling of the individually packaged goods on theapparatus, and for this reason it will not be mentioned again. Theindividually packaged goods 1 to 4 are in the order 3, 4, 2, 1 in thedirection of their destination, the TM VIII.

FIG. 4d shows the continuation of the sorting operation and the start ofdynamic and static sequencing. In order to produce the desireddestination order 1, 2, 3, 4 from the individually packaged goods order3, 4, 2, 1, the items 2 and 1 “overtake” the items 3 and 4. Item 5 istransported in the direction of TM II, the final sorting point allocatedto it. Item 6 is transported in the direction of TM I, “its” finalsorting point. Item 7 is about to reach its storage position. Items 8, 9and 10 are being moved in the direction of their intermediate storagelocations linked with their static sequencing.

FIG. 4e illustrates the continuation of sorting, dynamic and staticsequencing and storage. Item 2 has overtaken items 3 and 4, and item 1is located between 2 and 3, and therefore still has to pass item 2 inorder that the correct order is achieved. Item 5 is conveyed further inthe direction of TM II, and item 6 in the direction of TM I. Item 7 hasreached its storage position and is stopped there. Items 8, 9 and 10 arestopped at their intermediate storage locations linked with the staticsequencing.

FIG. 4f shows the further continuation of sorting, dynamic and staticsequencing and storage. Item 1 has overtaken items 2, 3 and 4, andtherefore the correct order 1, 2, 3, 4 has been reached. The sequence 1,2, 3, 4 is being transported in the direction of TM VIII, its finalsorting point. The dynamic sequencing has therefore been concluded.Items 5 and 6 have reached their final sorting positions TM II and TM Iand are being discharged onto the TM leading away.

Item 7 remains in its storage position until the removal from store isinitiated by the appropriate control command. Items 8, 9 and 10 remainsat their intermediate storage locations until the appropriate controlcommand to transport them away to the final sorting point TM IV arrives.

FIG. 4g shows the continuation of the sorting, the removal from storeand the completion of the static sequence. The sequence of items 1, 2,3, 4 has reached its final sorting point TM VIII with item 1 and isbeing discharged from the apparatus there. Items 5 and 6 have left theapparatus. The command to remove item 7 from store has already beengiven, and it is therefore on the way to its final sorting point, TM V.The control command to transport items 8, 9 and 10 away has been given,and they are being transported in the direction of TM IV whilstmaintaining their order, and item 8 has already reached TM VIII.

FIG. 4h shows the final state of the handling process. All theindividually packaged goods have been discharged from the apparatus, andare to some extent still on the discharging transport means assigned tothem as final sorting points.

What is claimed is:
 1. An apparatus for handing individually packagedgoods, which are fed and discharged lying beside and/or behind oneanother by transport means, having at least one input, at least oneoutput and at least one image processing device (3) for determininghandling information classifying the individually packed goods (1) fromrecorded images of the individually packaged goods (1), said apparatuscomprising: a plurality of conveying means (7) which are arranged in themanner of an array in one plane and move the individually packaged goods(1) in the plane, in each case at least in four directions at rightangles to one another, each of the individually packaged items (1)within the array area always being located on at least three conveyingmeans (7), and by at least one control device (6) for the independentactivation of each individual conveying means (7), at least with regardto conveying direction and period, in order to move the individuallypackaged goods (1) without collision in accordance with a handling plan,which links the handling to be carried out with the handling informationabout the individually packaged goods (1), for this purpose the locationand orientation of each classified item (1) being determined online bytracking the recorded images or outlines with the aid of the imageprocessing device (3) and/or further sensor devices.
 2. The apparatus asclaimed in claim 1, characterized in that the conveying means (7)possess a rotatable, spherical transport part, that is mounted without afixed axis and is driven in a transport direction that can be selectedfreely.
 3. The apparatus as claimed in claim 1, characterized in thatthe conveying speed and the acceleration and braking pattern of eachconveying means (7) can be selected by the control device (6).
 4. Theapparatus as claimed in claim 1, characterized in that in order todetermine the location and orientation of the individual items (1), asensor device which records the height profile is provided in additionto the image processing device (3) which records the occupied areas. 5.The apparatus as claimed in claim 1, characterized in that in order todetermine the location and orientation of the individual items (1), eachconveying means (7) has a pressure sensor which detects an item (1). 6.The apparatus as in claim 2, characterized in that the conveying speedand the acceleration and braking pattern of each conveying means (7) canbe selected by the control device (6).